Hole repair device

ABSTRACT

The present invention relates to a device to assist in filling a hole in a sheet or plate of any material, with a filler compatible with the material, the device comprising a flexible plate adapted to be inserted through the hole in the sheet or plate; a detachable attachment member adapted to extend generally perpendicularly from a surface of the flexible plate and including a connection to locate at least one locking member thereto; the locking member being detachably attachable to the attachment member so as to apply a tensile load on the attachment member thereby causing the flexible plate to bear on and be held adjacent to the hole.

TECHNICAL FIELD

The present invention relates to the sealing and/or repair of holes in asheet or plate of any materials. In particular it describes a device,and a process for the use of that device in the sealing and/or repair ofholes in sheets or plates of any material.

BACKGROUND ART

In the past, the repair of large holes in structures, such as holes inwalls, was a time consuming and difficult undertaking. Once complete,the results of the so-called hole repair were often viewed asunsatisfactory. Some of the more common problems associated with thepreviously available methods of hole repair included sagging and, inparticular, difficulties in obtaining a substantially flush finish withthe surface of the structure in which the hole had occurred.

Previous devices used to aid in the repair of holes in structuresincluded the use of wire mesh, or its equivalent, as a backing material.However, wire mesh suffered from the disadvantage that it was verydifficult to attach the mesh to the rear surface of the structuresurrounding the hole. Also, when the mesh was attached to the frontsurface of the structure surrounding the hole, and suitable fillingmaterials applied, the repaired hole suffered from a unsightly bulgecompared to the surrounding structure. Furthermore, when the fillingmaterial was applied to the mesh, the mesh was often lacking in materialstrength and consequently was subject to sagging.

The present invention provides a device where holes in sheets or platesof any material may be filled without encountering the problems ofsagging, whilst also obtaining a finish flush with the surface of thestructure undergoing repair.

DISCLOSURE OF THE INVENTION

According to a first embodiment of the invention there is provided adevice to assist in filling a hole in a sheet or plate of any material,with a filler compatible with said material, said device comprising:

a flexible plate adapted to be inserted through said hole in a sheet orplate;

a detachable, attachment member adapted to extend generallyperpendicularly from a surface of said flexible plate and includingmeans to locate at least one locking member thereto;

said locking member being detachably attachable to said attachmentmember so as to apply a tensile load on said attachment member therebycausing said flexible plate to bear on and be held adjacent to saidhole.

Typically the flexible plate may be adapted to be inserted through ahole in a sheet or plate of any material by a hinged mechanism withinthe flexible plate.

Preferably the flexible plate may be adapted to be inserted through ahole in a sheet or plate of any material by a concertina mechanismwithin the flexible plate.

More preferably the flexible plate may be adapted to be inserted througha hole in a sheet or plate of any material by virtue of the flexibleplate consisting of a flexible membrane.

Typically the flexible plate consists of a shearable material, allowingthe flexible plate to be custom sized to the hole to be repaired.

Typically, the flexible plate is formed of any suitable material, suchas timber, fibreglass, rubber, cardboard, or a plastic such aspolypropylene.

Typically the flexible plate includes at least one reinforcing rib.

Typically the flexible plate and/or reinforcing rib(s) is comprised of aseries of apertures to allow the filler to pass through the flexibleplate and/or reinforcing rib(s), thus providing maximal adhesion andpermitting the flexible plate to itself become an integral component ofthe filled surface.

Typically the flexible plate and/or reinforcing rib(s) may have adhesiveapplied to at least one surface of the flexible plate and/or reinforcingrib(s) to facilitate the attachment of the flexible plate and/orreinforcing rib(s) to the sheet or plate to be repaired, whilst alsofacilitating the adhesion of the suitable filler material to theflexible plate and/or reinforcing rib(s).

Typically the attachment member is attached to the surface of theflexible plate by a screw mechanism.

More typically the attachment member is attached to surface of theflexible plate by a snap-release mechanism.

Even more typically the attachment member is attached to surface of theflexible plate by a flange release mechanism.

Typically the locking member is attached to attachment member in such away as to accommodate holes of different thickness within the sheet orplate of any material.

Typically the locking member is attached to attachment member by a screwmechanism.

More typically the locking member is attached to attachment member by aclamping mechanism.

Even more typically the locking member is attached to attachment memberby a series of graduated notches into which the attachment member locksin.

According to a second embodiment of the invention there is provided amethod for filling a hole in a sheet or plate of any material with afiller compatible with said material, using the device in accordancewith the first embodiment of the invention comprising:

attaching attachment member to the flexible plate;

inserting the flexible plate and attached attachment member through thehole in the sheet or plate of any material;

communicating the locking member with the attachment member and surfaceof the sheet or plate of any material, so as to apply a tensile load onthe attachment member thereby securing the flexible plate to rear faceof the sheet or plate to substantially cover the hole;

partially filling hole with a filler compatible with the material of thesheet or plate;

allowing the filler to at least partially set;

detaching the attachment member together with the locking member;

filling remainder of hole with the suitable filling material.

Typically, the fillers used in the invention may be organic such aspolyester resisn or inorganic such as plaster of paris.

Typically, the fillers used in the present invention include:carbonates, fluorides, hydroxides, metals, oxides, silicates, sulfates,sulfides, celluloses, fatty acids, lignins, polyalkenes, polyamides,polyaromatics, polyesters, proteins, or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred forms of the present invention will now be described by way ofexample with reference to the accompanying drawings, wherein:

FIG. 1 is a perspective view of the flexible plate of the presentinvention.

FIG. 2 is a perspective view of the attachment member of the presentinvention.

FIG. 3 is a perspective view of the locking member of the presentinvention.

FIG. 4 is a sectional view showing the mounted state of the flexibleplate.

BEST MODE OR MODES OF CARRYING OUT THE INVENTION

To utilise the hole repair mechanism of the present invention, theattachment member (5) is attached to the flexible plate (1) by means ofan interlocking flange (8) located at one end of the attachment member(5), inserted through a slot (3) in the flexible plate (1), and adaptedin such a way as to securely attach the attachment member (5) to theflexible plate (1).

The flexible plate (1), with attached attachment member (5) is thenadapted to be inserted through a hole (11) in the sheet or plate (12 )of any material to be repaired. The insertion of the flexible plate (1),with attached attachment member (5) is facilitated by the flexiblenature of the flexible plate (1). This flexible nature may be achievedby virtue of the flexible plate (1) consisting of a plasticised fabricor a similar deformable material such as polypropylene.

Once the flexible plate (1), with attached attachment member (5), hasbeen inserted through the hole in the sheet or plate of any material tobe repaired, a locking member (9) is attached to the attachment member(5). The attachment of the locking member (9) to the attachment member(5) may be achieved by virtue of a slot (10) within the locking member(5) which communicates with a plurality of notches (7) and ridges (6)along the length of the attachment member (5). The locking member (9),via the slot (10) within the locking member (9), fits over theattachment member (5) and locks into one of a plurality of ridges (6)along the attachment member (5). The locking member (9) is locked intoone of these ridges (6) along the attachment member (5) in such a way asto exert a tensile load upon the attachment member (5) and therebycausing the flexible plate (1) to bear on and be held adjacent to thehole to be repaired.

Furthermore, the position of the locking member (9) in relation to theattachment member (5) is determined as a function of the thickness ofthe sheet or plate of any material surrounding the hole to be repaired.The distance between the locking member (9) and the flexible plate (1)can be varied by simply moving the locking member (9) up or down thelength of the attachment member (5), and by locking the slot (10) withinthe locking member (9) into a different notch (7) within the attachmentmember (5), thus accommodating sheets or plates of any material ofdifferent thickness. Also, for holes of varying lengths and widths, theflexible plate (1) consists of such a material which allows it to be cutto a shape to fit the particular dimensions of the hole in question.

In order to prevent the flexible plate (1) from falling in on itself,the flexible plate (1) also comprises at least one reinforcing rib (2)which acts to strengthen both the flexible plate (1) and the subsequentfilled and repaired hole. Furthermore, both the flexible plate (1) andthe reinforcing rib(s) (2) attached to the flexible plate consist of aseries of apertures (4) which allow a suitable filler material to passthrough the flexible plate (1) and/or reinforcing rib(s) (2), thusproviding maximal adhesion and permitting the flexible plate (1) toitself become an integral component of the filled surface, and thereforeincreasing the strength of the repaired hole.

Depending on the size of the hole to be repaired, and consequently, thesize of the flexible plate (1) required to substantially cover the hole,more than one locking member (9) may be required in order to bear thenecessary load on the attachment member (5) to ensure that the flexibleplate (1) sufficiently abuts the rear surface of the sheet or plate ofany material in which the hole is being filled.

The invention will now be described in greater detail by reference tospecific examples, which should not by construed as limiting on thescope thereof.

EXAMPLE 1

The following example describes the repair of a hole in a wall orceiling made of any material. Firstly, the flexible plate is placedagainst the hole, and the dimensions of the hole are traced upon theflexible plate. The plate is then cut to size, so as to fully cover thehole, whilst still having an effective overhang on all sides, thusensuring it will remain in place when pressure is applied to theattachment member. The attachment member is attached to the custom sizedflexible plate. The flexible plate with the attachment member in placeis then inserted through the hole in the wall or ceiling. Such aninsertion relies on the deformable nature of the flexible plate.

The operator then positions the flexible plate to cover the hole,leaving an approximately even overhang on all sides of the hole. Byexerting a force on the flexible plate and the attached attachmentmember, the operator ensures that the flexible plate abuts firmlyagainst the rear surface of the wall or ceiling undergoing repair. Thelocking member is then attached to the attachment member, therebycausing the flexible plate to bear on and be held adjacent to the holein the wall or ceiling as shown in FIG. 4.

Once the device is attached to the wall or ceiling, a filler material,such as a plaster or gypsum based filler common to the building trade,is then trowelled around the edges of the hole, and allowed to at leastpartially set. The locking member is then disengaged and removed, andthe attachment member is also disengaged and removed, or simply cut off.The appropriate filler is then applied to the remainder of the hole, andthe repair continued to produce a flush and finished surface.

EXAMPLE 2

The following example describes the repair of a hole in a sheet or panelof a motor vehicle or aircraft. The mechanics of the repair processinvolving the hole repair device of the present invention are inaccordance with the method described in Example 1. In this example, thefiller material used to repair the hole in a sheet or panel of a motorvehicle or aircraft would be one common to these trades, and would bepreferably one which is reinforced with suitable fibres.

EXAMPLE 3

The following example describes the repair of a hole in a sheet or panelof a marine craft. The mechanics of the repair process involving thehole repair device of the present invention are in accordance with themethod described in Example 1 and shown in Figure. In this example, thefiller material used to repair the hole in the sheet or panel of amarine craft would be one common to this trade, and would be preferablyone which is rich in plastic resin, such as epoxy resin.

Furthermore, when repairing marine craft, for example, repairing a holein a bouyancy tank, the hole repair device of the present inventionprovides the advantage that it negates the need to remove and/or cut-outsections of the upper deck in order to access and repair the hole.

What is claimed is:
 1. A device to assist in filling a hole in a sheet,or plate or panel of any material, with a filler compatible with saidmaterial, said device comprising: a flexible plate adapted to beinserted through said hole in said sheet, or plate or panel from a frontsurface to a back surface of said sheet, plate or panel; a detachable,attachment member attachable to said flexible plate to extend generallyperpendicularly from a surface of said flexible plate, a locking member,and a connection between said attachment member and said locking memberto secure said locking member thereto; said locking member beingdetachably attachable to said attachment member by said connection so asto apply a tensile load on said attachment member thereby causing saidflexible plate to bear on and be held against a back surface of saidsheet, or plate or panel adjacent to said hole, said flexible platebeing made of a unitary material to provide a uniform flexibility, saidmaterial being shearable to allow the flexible plate to be sized to thehole to be repaired, wherein said flexible plate has reinforcement ribsextending in crossing relation thereon, said plate being provided with aseries of apertures extending between said ribs for passage of fillermaterial therethrough to bond the flexible plate to said sheet, or plateor panel.
 2. The device of claim 1, wherein the flexible plate includesa hinged mechanism to enable insertion of said flexible plate throughsaid hole.
 3. The device of claim 1, wherein the flexible plate includesa concertina mechanism to enable insertion of said flexible platethrough said hole.
 4. The device of claim 1, wherein the flexible plateis formed of a flexible, deformable membrane to enable insertion of saidflexible plate through said hole.
 5. The device of claim 1, wherein theflexible plate is formed of a plastic material.
 6. The device of claim1, wherein the flexible plate is formed of polypropylene.
 7. The deviceof claim 1, wherein the flexible plate has a series of apertures toallow a filler compatible with said flexible plate to pass through theflexible plate.
 8. The device of claim 1, wherein the flexible plate hasadhesive applied to at least one surface thereof.
 9. The device of claim1, wherein the attachment member is attached to surface of the flexibleplate by a snap-release mechanism.
 10. The device of claim 1, whereinthe attachment member is attached to surface of the flexible plate by aflange release mechanism.
 11. The device of claim 1, wherein theconnection between the attachment member and the locking membercomprises a series of graduated notches into which the attachment memberlocks in.
 12. The device of claim 1, wherein the connection of thelocking member to the attachment member is variably adapted to attach tosaid attachment member to enable the repair of holes of different depthswithin said sheet, plate or panel.
 13. A method for filling a hole in asheet, plate or panel of a material with a filler compatible with saidmaterial, using the device according to claim 1 comprising: attachingsaid attachment member to said flexible plate; inserting the flexibleplate and attached attachment member through said hole in said sheet,plate or panel; communicating at least one locking member with theattachment member and a surface of the sheet, plate or panel, so as toapply a tensile load on the attachment member thereby securing theflexible plate to the back surface of the sheet, plate or panel tosubstantially cover the hole; partially filling hole with a fillercompatible with the material of the sheet, plate or panel to berepaired; allowing the filler to at least partially set and secure theflexible plate to the sheet, plate or panel; detaching the attachmentmember together with the locking member from the flexible plate, andfilling a remainder of hole with the filling material.
 14. The method ofclaim 13, wherein the suitable filler consists of an inorganic material.15. The method of claim 14, wherein the inorganic material includesplaster of paris.
 16. The method of claim 13, wherein the suitablefiller consists of an organic material.
 17. The method of claim 16,wherein the organic material includes polyester resin.
 18. A device asclaimed in claim 1, wherein said connection between the attachmentmember and the locking member provides axial adjustability of thelocking member on the attachment member with rotational fixationtherebetween.
 19. A device as claimed in claim 1, wherein saidconnection between the attachment member and the locking member includesnotches in one of said members and a slot in the other of said members,said slot being engagable with one of said notches to axially androtationally secure said members together in bearing engagement with afront surface of said sheet, plate or panel while applying said tensileload to said flexible plate to cause said flexible plate to bear againstthe back surface of the sheet, plate or panel.
 20. A device as claimedin claim 19, wherein said attachment member is axially and rotationallysecured to said flexible plate.